BR102023001721A2 - SYSTEM AND METHOD FOR AUTOMATIC INSERTION OF A WIRE CONTACT INTO A DESIGNATED WIRE CONTACT INSERTION HOLE OF A CONNECTOR - Google Patents

Abstract

system and method for automatically inserting a wire contact into a designated wire contact insertion hole of a connector. A method, system and computer program product are provided for automatically inserting a wire contact into an insertion hole of a connector. the methods include: controlling a robot having an end effector to position a wire contact near a connector using a wire gripper and an end effector separator device; controlling the robot to advance the separating device between two or more wires previously connected to the connector; control the robot to align the wire contact with the connector insertion hole; controlling the robot to advance the wire contact in the direction to the connector insertion hole and at least partially insert the wire contact into the insertion hole; control the robot to release the wire contact from the wire gripper; and controlling the robot to remove the wire gripper and separating device from between the two or more wires previously connected to the connector.

Description

TECHNICAL FIELD

[001] A method, system, and computer program product are provided in accordance with an exemplary embodiment for wire connector assembly through wire insertion, and more particularly, a method, system, and computer program product. computer for aligning and inserting a wire contact into an insertion hole of a connector in arbitrary insertion order.

FUNDAMENTALS

[002] Wire bundles consisting of a plurality of wires are used in a variety of industries to carry a myriad of different types of signals. The wire of a wire bundle assembly must often be terminated with a wire contact and the resulting wire end is inserted into a wire contact insertion hole of a connector, such as in a rubber grommet of a wire harness. connector. Because each wire in a wire bundle is unique and can carry a different type of signal, the wire ends of a wire bundle assembly must be inserted into specific wire contact insertion holes of a connector in order to make the appropriate connections.

[003] The wire ends of a wire bundle assembly can be manually inserted into respective wire contact insertion holes defined by a connector. Because wire bundle assemblies commonly include dozens or possibly hundreds of wires, this manual connection process can be relatively time-consuming and error prone and, as a result, can increase the cost of the total assembly including the wire bundle assembly. As such, automatic techniques for inserting the wire ends of a wire bundle assembly into the wire contact insertion holes of a connector have been developed in an effort to reduce the time spent making connections and to correspondingly reduce the cost of resulting set. However, wire bundle assembly machines generally require that the connectors be in a very restricted and controlled set of locations in order to increase the likelihood that the wire ends of the wire bundle assembly can be properly inserted into the insertion holes. connector wire contact. As such, wire harness assembly machines limit the flexibility with which connectors can be presented and as such are not suitable for all scenarios. Furthermore, automatic wire insertion techniques may improperly insert wire contacts into a connector, thus interrupting the automatic process and requiring correction.

BRIEF SUMMARY

[004] A method, system, and computer program product are provided for the wire connector assembly through wire insertion, and more particularly, for a method, system, and computer program product for aligning and inserting a contact of wire into an insertion hole of a connector in arbitrary insertion order. Embodiments include a system for automatically inserting a wire contact into a designated wire contact insertion hole of a connector, the system including: a robot having an end effector, wherein the end effector includes a wire gripper retaining the wire contact and a separating device; and a computing device, wherein the computing device is configured to: control the robot to position the wire gripper retaining the wire contact proximate to the connector; controlling the robot to advance the separating device anterior to one or more wires previously connected to the connector; controlling the robot to align the wire contact with the designated wire contact insertion hole of the connector; controlling the robot to advance the wire contact in the direction to the designated wire contact insertion hole of the connector and at least partially inserting the wire contact into the designated wire contact insertion hole; control the robot to release the wire contact from the wire gripper; and controlling the robot to remove the wire gripper and separating device from between the two or more wires previously connected to the connector.

[005] According to some embodiments, the computing device configured to control the robot to advance the separator device anteriorly to the one or more wires previously connected to the connector is further configured to: control the robot to advance the separator device from a first position relative to the wire gripper to a second position relative to the wire gripper, wherein the first position is further from the connector than the wire gripper, and wherein the second position is closer to the connector than the wire gripper; and controlling the robot to actuate the separating device anteriorly to the one or more wires at a position between the wire gripper and the connector. According to certain embodiments, the computing device configured to control the robot to advance the separator device anteriorly to the one or more wires previously connected to the connector is further configured to: control the robot to move the separator device from the second position relative to the wire gripper. wire to the first position relative to the wire gripper with the separating device engaged with the one or more wires.

[006] According to certain embodiments, the computing device configured to control the robot to advance the wire contact in the direction to the designated wire contact insertion hole of the connector and at least partially insert the wire contact into the wire contact hole. Designated wire contact insertion further includes causing the robot to: advance the wire contact in the direction to the designated wire contact insertion hole of the connector and at least partially insert the wire contact into the wire contact insertion hole designated unobstructed by the one or more wires previously connected to the connector. The computing device of an example embodiment is further configured to: determine occupied wire contact insertion hole positions of the connector, wherein occupied wire contact insertion holes are occupied with the one or more wires previously connected to the connector ; and identifying a path for an insertion axis of the designated wire contact insertion hole of the connector, wherein the path is perpendicular to the insertion axis.

[007] According to some embodiments, the computing device configured to identify the path to the insertion axis of the designated wire contact insertion hole of the connector, wherein the path is perpendicular to the insertion axis, is further configured to identify the path to the insertion axis of the designated wire contact insertion hole of the connector based on a maximum distance between the path and at least one of the occupied wire contact insertion holes of the connector. The computing device configured to identify the path to the insertion axis of the designated wire contact insertion hole of the connector, wherein the path is perpendicular to the insertion axis, is, in some embodiments, configured to: identify an angle of the path to the insertion axis of the designated wire contact insertion hole of the connector with respect to the vertical geometric axis, wherein the computing device configured to control the robot to position the wire gripper retaining the wire contact proximate to the connector is, in some embodiments, further configured to control the robot to rotate to the path angle with respect to the connector.

[008] According to some embodiments, the one or more wires previously connected to the connector include two or more wires previously connected to the connector, the computing device configured to control the robot to advance the separating device anteriorly to the one or more wires previously connected to the connector includes the computing device configured to control the robot to advance the separator device between the two or more wires previously connected to the connector, wherein the separator device of an exemplary embodiment includes a first separator element and a second separator element, in that the computing device configured to control the robot to advance the separating device between the two or more wires previously connected to the connector includes, in some embodiments, the computing device configured to actuate a point at which the first separating element meets the second element separator between the two or more wires previously connected to the connector along a path to an insertion axis of the designated wire contact insertion hole of the connector, wherein the path is perpendicular to the insertion axis.

[009] Embodiments provided herein include a method for automatically inserting a wire contact into a designated wire contact insertion hole of a connector, the method including: controlling a robot having a terminal effector to position the wire contact nearby to the connector using a wire gripper and end effector separator device; controlling the robot to advance the separating device between two or more wires previously connected to the connector; controlling the robot to align the wire contact with the designated wire contact insertion hole of the connector; controlling the robot to advance the wire contact in the direction to the designated wire contact insertion hole of the connector and at least partially inserting the wire contact into the designated wire contact insertion hole; control the robot to release the wire contact from the wire gripper; and controlling the robot to remove the wire gripper and separating device from between the two or more wires previously connected to the connector.

[0010] According to some embodiments, controlling the robot to advance the separating device between the two or more wires previously connected to the connector includes: controlling the robot to advance the separating device from a first position relative to the wire gripper to a second position relating to the wire gripper, wherein the first position is further from the connector than the wire gripper, and wherein the second position is closer to the connector than the wire gripper; and controlling the robot to actuate the separating device between the two or more wires at a position between the wire gripper and the connector. Controlling the robot to advance the separating device between the two or more wires previously connected to the connector further includes, in some embodiments, controlling the robot to move the separating device from the second position relative to the wire gripper to the first position relative to the wire gripper. with the separating device engaged between the two or more wires.

[0011] According to some embodiments, controlling the robot to advance the wire contact in the direction to the designated wire contact insertion hole of the connector and at least partially insert the wire contact into the designated wire contact insertion hole further includes advancing the wire contact in the direction to the designated wire contact insertion hole of the connector and at least partially inserting the wire contact into the designated wire contact insertion hole between the two or more wires previously connected to the connector. The method of some embodiments further includes: determining occupied wire contact insertion hole positions of the connector, wherein occupied wire contact insertion holes are occupied with the two or more wires previously connected to the connector; and identifying a path for an insertion axis of the designated wire contact insertion hole of the connector, wherein the path is perpendicular to the insertion axis.

[0012] According to certain embodiments, identifying the path to the insertion axis of the designated wire contact insertion hole of the connector, wherein the path is perpendicular to the insertion axis, further includes: identifying the path to the geometry axis of the designated wire contact insertion hole of the connector based on a maximum distance between the path and at least one of the occupied wire contact insertion holes of the connector. Identifying the path to the insertion axis of the designated wire contact insertion hole of the connector, wherein the path is perpendicular to the insertion axis, additionally includes in some embodiments: identifying an angle of the path to the insertion axis of the hole of insertion of the designated wire contact of the connector with respect to the vertical axis, wherein controlling the robot to position the wire gripper retaining the wire contact proximate to the connector further includes controlling the robot to rotate to the angle of the path with respect to the connector.

[0013] According to some embodiments, the separating device includes a first separating element and a second separating element, wherein controlling the robot to advance the separating device between two or more wires previously connected to the connector includes actuating a point at which the first separating element meets the second separating element between the two or more wires previously connected to the connector along a path to an insertion axis of the designated wire contact insertion hole of the connector, wherein the path is perpendicular to the geometric axis of insertion.

[0014] Embodiments provided here include an apparatus including at least one processor and at least one memory including computer program code, the at least one memory and the computer program code are configured to, with the processor, cause the apparatus at least: controls a robot having an end effector to position a wire contact proximate to the connector using a wire gripper and an end effector separator device; control the robot to advance the separating device between two or more wires previously connected to the connector; control the robot to align the wire contact with the designated wire contact insertion hole of the connector; control the robot to advance the wire contact in the direction to the designated wire contact insertion hole of the connector and at least partially insert the wire contact into the designated wire contact insertion hole; control the robot to release the wire contact from the wire gripper; and control the robot to remove the wire gripper and separator device from between the two or more wires previously connected to the connector.

[0015] According to some embodiments, causing the apparatus to control the robot to advance the separator between the two or more wires previously connected to the connector includes causing the apparatus to: control the robot to advance the separator device from a first position relative to the wire gripper to a second position relative to the wire gripper, wherein the first position is further from the connector than the wire gripper, and wherein the second position is closer to the connector than the wire gripper; and control the robot to actuate the separating device between the two or more wires at a position between the wire gripper and the connector. Causing the apparatus of some embodiments to control the robot to advance the separating device between the two or more wires previously connected to the connector further includes causing the apparatus to control the robot to move the separating device from the second position relative to the wire gripper to the first position relative to the wire gripper with the separating device engaged between the two or more wires. Causing the apparatus of some embodiments to control the robot to advance the wire contact in the direction to the designated wire contact insertion hole of the connector and at least partially insert the wire contact into the designated wire contact insertion hole includes further cause the apparatus to: advance the wire contact in the direction to the designated wire contact insertion hole of the connector and at least partially insert the wire contact into the designated wire contact insertion hole between the two or more wires previously connected to the connector.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Having thus described certain exemplary embodiments of the present invention in general terms, reference will be made hereinafter to the accompanying drawings, which are not necessarily drawn to scale, and in which: Figure 1 is a perspective view of a connector according to an exemplary embodiment of the present invention; Figure 2 is a front view of the connector of Figure 1 in accordance with an exemplary embodiment of the present invention; Figure 3 is a block diagram of the system that can be specifically configured in accordance with an exemplary embodiment of the present invention; Figure 4 represents a robot end effector, wire gripper, separation device, and imaging device in accordance with an exemplary embodiment of the present invention; Figure 5 illustrates various views of recovering a wire having a wire contact using a wire gripper in accordance with an exemplary embodiment of the present invention; Figure 6 illustrates images of a connector obtained by the robot end effector imaging devices of Figure 4 in accordance with an exemplary embodiment of the present invention; Figure 7 is a flowchart of a process for aligning a wire contact with a designated wire contact insertion hole in accordance with an exemplary embodiment of the present invention; Figure 8 is an illustration of a robot end effector including imaging devices, a wire gripper, and the separator device, in accordance with an exemplary embodiment of the present invention; Figure 9 is an illustration of another view of the robot end effector of Figure 8, including imaging devices, a wire gripper, and the separator device in accordance with an exemplary embodiment of the present invention; Figure 10 is a two-view illustration of an operation in the process for inserting a wire contact into a designated wire contact insertion hole of a connector in accordance with an exemplary embodiment of the present invention; 11 is a two-view illustration of another operation in the process for inserting a wire contact into a designated wire contact insertion hole of a connector in accordance with an exemplary embodiment of the present invention; 12 is a two-view illustration of another operation in the process for inserting a wire contact into a designated wire contact insertion hole of a connector in accordance with an exemplary embodiment of the present invention; 13 is a two-view illustration of yet another operation in the process for inserting a wire contact into a designated wire contact insertion hole of a connector in accordance with an exemplary embodiment of the present invention; 14 is a two-view illustration of another operation in the process for inserting a wire contact into a designated wire contact insertion hole of a connector in accordance with an exemplary embodiment of the present invention; 15 is a two-view illustration of yet another operation in the process for inserting a wire contact into a designated wire contact insertion hole of a connector in accordance with an exemplary embodiment of the present invention; 16 is a two-view illustration of another operation in the process for inserting a wire contact into a designated wire contact insertion hole of a connector in accordance with an exemplary embodiment of the present invention; Figure 17 is a diagram of a wire connector with previously installed wires and a path for advancing a wire contact to an insertion axis for a designated wire contact insertion hole of the connector in accordance with an example embodiment of the connector. present invention; Figure 18 is a pseudo code representation for optimizing an approach angle for advancing a wire contact to an insertion axis for a designated wire contact insertion hole of the connector in accordance with an exemplary embodiment of the present invention; and Figure 19 is a flowchart of a method for inserting a wire contact into a designated wire contact insertion hole of a connector, to which two or more wires have previously been connected in accordance with an exemplary embodiment of the present invention.

DETAILED DESCRIPTION

[0017] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all aspects, are shown. In fact, the invention can be embodied in many different forms and should not be construed as limited to the aspects set forth herein. On the contrary, these aspects are provided so that this invention will satisfy legal requirements. The same numbers refer to the same elements throughout the description.

[0018] A method, system, and computer program product is provided in accordance with an example embodiment described herein for automatically aligning wire contacts with insertion holes of a connector, and more particularly, to a method, system, and computer program product. , and computer program product for aligning and inserting a wire contact into an insertion hole of a connector in arbitrary insertion order. The process described here detects wire contact and insertion holes simultaneously using cameras mounted on the robotic end effector. Using simultaneous sensing, embodiments of the described methods provide feedback for the corrective movements of a robot arm used to insert the wire contacts into the connector insertion holes. The movements of the robot arm align the wire contact with a designated wire contact insertion hole for successful insertion into an appropriate hole of a connector. However, wire connectors often include a plurality of wires inserted into the connector, so wire contacts installed in the connector after several wire contacts have already been inserted may face additional challenges due to the wire leads extending from the connector and obstructing both a view of the insertion line for inserting a wire contact into an insertion hole of a connector. The embodiments described here overcome the challenges of inserting a wire contact into an insertion hole of a connector, when a plurality of wire contacts are already inserted into other insertion holes of the connector.

[0019] Wire bundle assembly including affixing one or more wire connectors to the wire bundle has traditionally been a labor-intensive process, which is both time-consuming and introduces opportunities for errors in the assembly. The embodiments described herein allow for the automatic assembly of wire bundles and their associated wire connectors in a manner that does not require a specific order of insertion. Embodiments provide a process for robotically retrieving and inserting wire contacts into connectors, particularly allowing insertions in an arbitrary insertion hole order. Embodiments include a separation mechanism for separating wires from previously inserted wire contacts, although cameras proximate to a gripper grasping the wire provide contact hole alignment. Camera images are processed to control the alignment and insertion of a wire contact into the connector. Embodiments provide for automatic insertion of wire ends and their respective wire contacts into connectors without the need for a specific insertion order. Embodiments described herein may use a robot arm with a robot end effector to insert wires, supporting a flexible arrangement of connectors and wires.

[0020] A method, system and computer program product are provided in accordance with an example embodiment, in order to provide a free path for a wire contact to be inserted into an insertion hole of a connector. Embodiments use a separation mechanism to separate wires previously inserted into the connector near the connector so that cameras can identify the wire contacts and wire contact insertion holes defined by a connector to align and insert the wire contacts into the hole. wire contact insertion. Although the method, system and computer program product may be configured to identify the wire contacts and wire contact insertion holes of a variety of different types of connectors, the connectors generally define a plurality of wire contact insertion holes of wire or connector holes within a housing with the wire contact insertion holes within a housing arranged in a predefined configuration. Different connectors may include different numbers of wire contact insertion holes and may include wire contact insertion holes arranged in different configurations.

[0021] An example of a connector is represented in figures 1 and 2 in the form of a connector 10. As shown, the connector 10 includes a housing 12 and a rubber grommet 16 disposed therein. Although the housing 12 may be configured differently for other types of connectors, the connector housing 10 of the embodiment of Figures 1 and 2 is externally threaded to facilitate, for example, secure threaded engagement of a wire bundle assembly or other connector with the same. The connector 10 of Figures 1 and 2 also includes a radially extending flange defining a plurality of openings 13, such as for receiving screws or other fasteners for mounting the connector to an assembly. Although the connector 10 of Figure 1 has a cylindrical shape, the connector of other example embodiments may have different sizes and shapes. With respect to the example connector of Figures 1 and 2, a rubber grommet 16 is disposed within the housing and the rubber grommet defines a plurality of wire contact insertion holes 18. The contact insertion holes of wires 18 defined by the rubber grommet 16 are configured, e.g., sized, and shaped, so that a wire end consisting of a wire contact connected, e.g., corrugated, to the end of a wire, is inserted in, and mechanically retained within, the wire contact insertion hole 18.

[0022] As shown by the example of the connector 10 of figures 1 and 2, the plurality of wire contact insertion holes 18 defined by the rubber grommet 16, are arranged in a defined pattern. In some embodiments, not all of the wire contact insertion holes of a connector 10 will be utilized; instead, only a subset of the wire contact insertion holes will receive and make electrical connection to corresponding wire ends of the bundle assembly. of wires. As illustrated in Figure 2, wire contact insertion holes 18 defined by rubber grommet 16 that will not be used in conjunction with a particular application can be eliminated from further consideration by inserting a plug 20 into the respective wire contact insertion hole. wire contact defined by rubber grommet. Although a connector 10, which can be analyzed in accordance with an exemplary embodiment of the present invention, is depicted in Figures 1 and 2 and will be described hereinafter, the method, system and computer program product of an exemplary embodiment may be used in conjunction with a wide variety of other connectors and the connector is illustrated and described by way of example, but not limitation.

[0023] Plugs 20 of a wire connector can be used to fill holes that cannot be used for the wire bundle within an assembled housing. For example, a connector may have twenty wire contact insertion holes 18; however, a bundle of wires feeding connector 10 may include only eighteen wires and corresponding wire contacts. In such an embodiment, the unused wire contact insertion holes may be plugged with plugs 20 so that there is less, or possibly no, opportunity for water, moisture, or other corrosive/oxidizing substance to enter the connector and contaminate the wires and wire contacts.

[0024] As is evident from the connector 10 of Figures 1 and 2, connectors may include a plurality of wire contact insertion holes 18, in which the wire contacts are received. When the wire contacts of respective wires are inserted, the connector becomes crowded with a set of wires that is particularly dense near the connector. This makes continued insertion of wire contacts into the connector's remaining available insertion holes difficult, particularly when computer vision is used to identify the available insertion holes for alignment. The embodiments provided here facilitate insertion of wire contact in arbitrary order. This capability improves robotic alignment and insertion of wire contacts into connector insertion holes.

[0025] Referring now to Figure 3, a system for separating wires having contacts previously inserted into a connector, identifying the wire contact insertion holes 18 of the connector 10, and inserting the wire contacts into corresponding contact insertion holes of available wire 18 is represented. As shown, system 30 includes cameras 32 configured to obtain images of connector 10. Although plural cameras are indicated in Figure 3, embodiments may employ a single camera, or may employ a single camera operating with mirrors to provide multiple perspectives of connector 10 using a single camera. The cameras described here are one type of imaging device, in which a variety of imaging device types can be used in place of a camera. Imaging devices generally obtain an image of the device's field of view. A camera, as described here, obtains an image of the field of view in the visible light spectrum and processes the image accordingly. Cameras 32 may be configured to obtain a grayscale image of connector 10. Alternatively, cameras 32 may be configured to obtain color images of connector 10. In one embodiment, in which color images of connector 10 are obtained, the image associated with each different color channel of the cameras 32, such as the red, green, and blue color channels, can be averaged to create a composite image for subsequent analysis and review. Alternatively, the different color channels of the cameras 32 can be separately analyzed. The cameras 32 are generally configured to obtain images of the front face of the connector 10, as shown in Figure 2, so that the plurality of wire contact insertion holes 18 defined by the rubber grommet 16 are clearly visible. The cameras 32 may also be configured to image the wire contacts during alignment of the wire contacts with the connector 10. As such, the image obtained by the cameras 32 of an example embodiment may be obtained at a plurality of angles to provide Different perspectives of the 10 connector and wire contacts.

[0026] In addition to the cameras 32, the system 30 of Figure 3 includes a computing device 34 configured to analyze images of the connector 10 obtained by the cameras and identify the connector's wire contact insertion holes and wire contacts. System 30 may also be configured to identify plugs 20 within a connector 10. As also shown in Figure 3, system 30 of an exemplary embodiment also includes, or is in communication with, a robot 44 and, more particularly, a robotic terminal effector, which is used to insert the ends of wires/contacts into respective insertion candidate contact insertion holes of the connector 10 based on the identification of the wire contact insertion holes of the connector and the wire contacts by the computing 34.

[0027] Although identifying wire contact insertion holes in the connector is generally less complex, when a connector does not have any wires inserted into the connector, the embodiments described here allow the system of Figure 3 to move wires that are inserted into the connector. connector to provide visibility to the connector's available wire contact insertion holes. In this way, insertion holes that are obscured by wires inserted into the connector can be made visible by separating wires around the available wire contact insertion hole to provide cameras 32 with visibility of the available wire contact insertion hole for the connector. alignment and insertion of a wire contact.

[0028] The computing device 34 may be configured in a variety of ways and as such may be incorporated as a personal computer, a tablet computer, a computer workstation, a mobile computing device such as a smart phone , a viewing being, or similar. Regardless of the manner in which the computing device 34 is incorporated, the computing device of an exemplary embodiment includes or is otherwise associated with processing circuitry 36, memory 38, and optionally a user interface 40 and an interface. communication module 42 to perform the various functions described herein. The processing circuitry 36 may, for example, be incorporated as various means including one or more microprocessors, one or more coprocessors, one or more multi-core processors, one or more controllers, one or more computers, various other processing including integrated circuits, such as, for example, an ASIC (application specific integrated circuit) or FPGA (programmable logic gate network), or some combination thereof. In some example embodiments, the processing circuitry 36 is configured to execute instructions stored in memory 38 or otherwise accessible to the processing circuitry. These instructions, when executed by processing circuitry 36, may cause computing device 34, and in turn system 30, to perform one or more of the functionalities described herein. As such, computing device 34 may comprise an entity capable of performing operations in accordance with an exemplary embodiment of the present invention, although configured accordingly. Thus, for example, when the processing circuitry 36 is incorporated as an ASIC, FPGA, or the like, the processing circuitry and, correspondingly, the computing device 34, may comprise hardware specifically configured to conduct one or more operations. described here. Alternatively, as another example, when processing circuitry 36 is incorporated as an executor of instructions, as may be stored in memory 38, the instructions may specifically configure the processing circuitry and, in turn, the processing device. computing 34, to perform one or more algorithms and the operations described herein.

[0029] Memory 38 may include, for example, volatile and/or non-volatile memory. Memory 38 may comprise, for example, a hard disk, random access memory, cache memory, flash memory, an optical disk (e.g., a compact disc read-only memory (CD-ROM), digital versatile disc (DVD-ROM), or similar), circuits configured to store information, or some combination thereof. In this regard, memory 38 may comprise any computer-readable, non-transitory storage medium. Memory 38 may be configured to store information, data, applications, instructions, or the like, to allow computing device 34 to perform various functions in accordance with exemplary embodiments of the present invention. For example, memory 38 may be configured to store program instructions for execution by processing circuitry 36.

[0030] The user interface 40 may be in communication with the processing circuitry 36 and the memory 38 to receive user input and/or to provide an audible, visual, mechanical, or other output to a user. As such, user interface 40 may include, for example, a display for providing an image obtained by camera 32 and/or an image visually representing the closest match between candidate contacts and a predetermined pattern, as described below. Other examples of user interface 40 include a keyboard, a mouse, a control stick, a microphone and/or other input/output mechanisms.

[0031] The communication interface 42 may be in communication with the processing circuitry 36 and the memory 38 and may be configured to receive and/or transmit data, such as by receiving images from the camera 32 and transmitting information, as a list of insertion candidate contact insertion holes, contact ID numbers, and insertion candidate contact insertion hole locations in a connector-based coordinate system, for a robot 44 and/or a robotic end effector. Although referenced here as insertion candidate contact insertion holes, the contact ID numbers and insertion candidate contact insertion hole locations, the list of insertion candidate contact insertion holes, the contact ID numbers and locations of the insertion candidate contact insertion holes shall be interpreted to be associated with the insertion candidate contact insertion holes themselves and/or wire contacts aligned with the respective insertion candidate contact insertion holes in those embodiments which include such wire contacts. Communication interface 42 may include, for example, one or more antennas and supporting hardware and/or software to enable communications with a wireless communication network. Additionally or alternatively, the communications interface 42 may include circuitry for interacting with the antenna(s), to cause transmission of signals through the antenna(s), or to manipulate the reception of signals received by the antenna(s). antenna(s). In some environments, communication interface 42 may alternatively or also support wireless communication.

[0032] Referring now to Figure 4, an exemplary embodiment of a system carrying out the methods described herein is shown, including a robot end effector 100, which may include a tool head having three or more degrees of freedom, and the imaging devices including a first camera 102 and a second camera 104. The robotic end effector 100 may carry a wire 111 in a wire gripper 108 including a wire contact 114 at the front end of the wire 111. The robot end effector One of the example embodiments further includes the separator device 119. A connector 110 is disposed in a fixed location as it is approached by the robotic end effector 100. The connector is illustrated with a single designated wire contact insertion hole 116; however, the single designated wire contact insertion hole is shown, for ease of understanding, such connectors will include a plurality of designated wire contact insertion holes, and in some cases, a plurality of previously inserted wires. The two cameras 102, 104 are mounted on the robotic end effector 100 in such a way as to view both the wire 111 including the wire contact and the connector 110 simultaneously.

[0033] Although the embodiment of Figure 4 includes two cameras, the embodiments may include more cameras. Furthermore, a single camera can be used in conjunction with mirrors to observe different perspectives of the wire contact and connector using the single camera. Capturing multiple perspectives, such as by using two or more cameras, can allow precise positioning of the wire contact and connector as they are joined. In an exemplary embodiment, four cameras are affixed to the robot end effector with a first pair of cameras positioned above the wire gripper, oriented downwardly over the wire gripper, and a wire contact captured thereon. The first pair of cameras positioned so that a surface of a connector is within the field of view when the wire contact is placed in the direction towards the connector. A second pair of cameras can be mounted near the gripper tip to obtain an unobstructed view of the designated wire contact insertion hole prior to insertion. Camera images can rely on sufficient lighting to obtain maximum quality images and to provide the most accurate alignment. As such, lamps, such as LED lamps, can be affixed to the robot end effector for consistent illumination for camera images.

[0034] The separating device 119 of the illustrated embodiment is movable towards, and away from, a connector 110, such as along a track 117, and movement may be communicated, for example, by a pneumatic or hydraulic cylinder along the track or by a servo motor, for example. In an example, in which the separating device 119 is movable using a pneumatic cylinder, the pneumatic cylinder may be controlled by a solenoid, which is turned on and off by the control software for automatic wire pickup and insertion of the wire contact into the hole. of designated wire contact insertion.

[0035] The embodiments described here are configured to assemble a wire connector by picking up and inserting wires with wire contacts affixed to wire contact insertion holes of a connector. For this purpose, wires must first be obtained and grasped by wire gripper 108 prior to alignment and insertion into a connector. An example process for recovering wires may include placing wires with contacts affixed to them, such as in a wire holder. The robot end effector 100 may be moved to position the wire gripper 108 above the stationary wire. The separator device 119 and the wire gripper 108 may each be opened so that the end effector can move the separator device 119 anterior to the wire (between a first separator element 119A and second separator element 119B, described and illustrated in more detail below ) and the wire can be positioned between the gripping elements of the wire gripper 108.

[0036] Figure 5 illustrates a schematic of a sequence of movements to grasp a stationary thread. The wire gripper 108 and separator device 119 are depicted separately from the remaining components of the robot end effector for ease of understanding. As shown at 151, the wire gripper 108 and the separating device including the first separating element 119A and second separating element 119B are moved to a predetermined location near a yarn holder (not shown) that holds the wire 111 in a position stationary. The initial position may include an orientation in which the first separator element 119A and the second separator element 119B are in contact with each other below the wire gripper 108. In such a scenario, the first separator element 119A and second separator element 119B may 5 , images may be captured, such as from cameras 102 and 104 of Figure 4. A controller processes the images and computes machine commands to move the robot end effector 100. The captured images include wire 111 and wire contact 114 and the gripping elements of the wire gripper 108. The controller can use these images, captured from different orientations, to estimate the position of the wire 111 with respect to the wire gripper 108. Given this estimated position, the robot end effector is commanded by the controller to move to translate the wire gripper 108 so that the wire 111 is between the gripping elements of the wire gripper. These commands can be executed on a control link, in which images are captured, the wire location is estimated, and movement commands are executed until the wire position is between the wire gripper gripping elements within a limit distance (e.g. one millimeter).

[0037] Once the wire gripper 108 is aligned with the wire 111 as shown at 152 of Figure 5, the wire gripper 108 closes the gripping elements to retain the wire as shown at 153. The wire gripper 108 can push down on wire 111 to cause wire 111 to be released from a wire holder. The wire gripper 108 is configured to grip the wire 111 just behind the wire contact 114 to facilitate insertion of the wire contact 114 into a designated wire contact insertion hole of the connector. The yarn gripper 108 of an exemplary embodiment is configured to grip the yarn and vary between a secure grip of the yarn and a tight, looser grip of the yarn, wherein in the looser grip of the yarn, the yarn gripper 108 can be moved along a length of wire to the appropriate position near the wire contact 114. Sliding the wire gripper 108 along the wire to the appropriate position can be accomplished in a closed-link control using images captured by the cameras to determine a distance between the wire gripper 108 and the wire contact 114. Once the wire is clamped by the wire gripper 108 near the wire contact 114, the robot end effector moves the clamped wire to a position for alignment and inserting the wire contact into the designated wire contact insertion hole of the connector.

[0038] Although the operation of the separator device 119 is described in more detail below, the process of aligning the wire contact 114 with the designated wire contact insertion hole of the connector 110 is described here without regard to visual obstructions that may be present, when a plurality of wires are already connected to the connector. In accordance with example embodiments described herein, images are obtained of wire 111 and wire contact 114 together with connector 110 from more than one perspective. Using the different perspectives, a line is identified that extends in the direction of the wire and wire contact and a hole in the connector that is the target hole for the wire is identified. Figure 6 illustrates images 120, 122 obtained by two different imaging devices, such as cameras 102 and 104 of Figure 4, of wire 111 including wire contact 114 and connector 110, specifically the wire insertion hole. identified contact of designated wire 116 of the connector, into which wire 111 is to be inserted. A line, identified through multiple perspectives, provides at least one stereoscopic indication of the relationship between the wire contact and the target hole of the connector into which the hole is to be inserted, and can be identified based on the axial projection of the wire 111 and of wire contact 114. Based on the identified line of the images, a move command can be computed, which would place the hole on the line in at least two images. This may initially establish a rotation of the end effector to place the tip of the wire gripper 108 perpendicular to the surface of the connector. To place the hole on the line, a motion is established parallel to the connector surface to align the line with the appropriate target hole of the connector. A motion command is the desired displacement of the robot end effector in three-dimensional Cartesian space. Aligning the wire contact with the hole places the wire in an appropriate position to allow the robot to move the wire along the line toward the appropriate connector hole for insertion.

[0039] Embodiments described here can calibrate the forward cameras by using them to align the wire with the target hole of the connector. The purpose of calibration is to compute a mapping from three-dimensional Cartesian coordinates to two-dimensional image coordinates. Calibration can be performed before the wires are fed to the end effector robotic wire gripper. Calibration is not necessary before each wire insertion or before each connector change, but may be necessary when camera settings change, such as focus, zoom, orientation, etc.

[0040] Embodiments use image analysis to identify wire contact insertion holes in a connector, and to align a wire contact with a designated wire contact insertion hole. For each camera image analyzed, a line describing the wire contact and a target hole location are determined to ensure proper alignment. Based on this information, a corrective movement for the robot end effector can be computed if the wire contact is not aligned with the wire contact insertion hole. According to an example embodiment, a designated wire contact insertion hole location is identified in two or more camera images. The three-dimensional location “p” of the target hole in the end effector coordinate system is then computed. To compute this location, an optimization algorithm is used, which minimizes the sum of squared distances between the two-dimensional image locations of the target hole and the projections of the three-dimensional location in the camera images. A non-limiting example for an optimization includes Powell's method.

[0041] A location “r” is computed in the coordinate system of the terminal effector, which projects closest to a wire contact line in each image. This location is optionally constrained to be in one plane of the connector surface. An optimization algorithm can be used to compute “r”. Based on the resulting values of “p” and “r”, the corrective movement can be computed as c = p - r. Movement of the terminal effector can then be accomplished.

[0042] The designated wire contact insertion hole of the connector for the wire contact is used to facilitate insertion of a wire contact into a respective wire contact insertion hole of the connector. In this regard, a wire is identified by a wire diagram, or the like, and is inserted into a particular wire contact insertion hole of the connector with the particular wire contact insertion hole in a housing identified by a number of Contact ID, which is identified on the connector via the aforementioned identifier map for the connector.

[0043] The process of aligning and inserting a wire into an available wire contact insertion hole of a connector, as illustrated with respect to figures 4 and 6, is achieved through clear visibility to the connector and the wire contact insertion holes. wire contact in it. However, when a connector is constructed by inserting multiple wires into respective wire contact insertion holes, the visibility of the available connector and wire contact insertion holes decreases drastically. The embodiments described here overcome this problem by using the separation device 119 from the robot end effector 100 depicted in Figure 4.

[0044] Figure 7 illustrates the general process of aligning a wire contact with a designated wire contact insertion hole of a connector with reference to the system depicted in Figure 4. After a wire 111 is grasped by the wire gripper 108 of the end effector 100, whether the wire is placed in the wire gripper or picked up by the wire gripper, images can be obtained by cameras 102, 104 mounted on the end effector at 150. In these images, the wire contact 114 is detected and its direction obtained as shown at 152. The robot can then move the wire contact 114 to be close to the connector surface at 154. In this position, the cameras again obtain the images at 156 to include the wire contact 114 and the connector 110. From these images, two processes are computed: first the wire contact direction is updated by 158; and, second connector holes are detected at 160. By combining the output of these processes, the system computes a move command at robot end effector coordinates to align the contact with a designated wire contact insertion hole at 162.

[0045] In accordance with some embodiments, iterative corrective movements may be performed to align the wire contact 114 with the designated wire contact insertion hole of the connector 110. To accomplish this, after the robot performs the first illustrated alignment process In Figure 7, camera images are again obtained, and both contact and target hole positions are updated. If this update produces a corrective movement command below a threshold (for example, below 0.1 millimeters), the robot cannot perform the correction and instead continues to move the contact in the direction toward the connector surface. . The direction of movement of the wire contact towards the connector surface corresponds to the direction of the contact in three dimensions, as obtained from the camera images. If the updated wire contact position produces a correction above the threshold, the robot can then make the corrective movement and obtain new images, whereby the aforementioned process is repeated until the correction is below the threshold.

[0046] The number of corrective iterations of the alignment process can be limited, such as three attempts. After this limit, the robot may abort the alignment process and indicate an error, such as through a user interface error message. Alternatively, the robot can start again by moving the contact close to the connector surface as before.

[0047] Wire contact detection and designated wire contact insertion hole detection are necessary to align the contact with a designated wire contact insertion hole and to understand the direction of movement for the robot end effector , once when the contact is aligned. However, designated wire contact insertion holes of a connector may be obscured by wire contact wires previously inserted into the connector. Contact hole detection is imperative to properly identify the correct connector insertion hole into which the wire contact is to be inserted. In each camera image including the connector, contact insertion holes are detected.

[0048] Embodiments described herein provide a mechanism whereby the previously inserted wire contact wires of the connector are separated to provide a line of sight for cameras to capture images of wire contact insertion holes. available. Figure 8 illustrates the end effector in more detail than the schematic of Figure 4. As shown, the robot end effector 200 carried by a robot (not shown) includes a first camera 202, wherein a second camera may be positioned in an opposite side of the end effector for a second image capture angle. The end effector 200 further includes the wire gripper 208 configured to grip a wire 211 including a wire contact 214. The separator device 219 is illustrated positioned in front of the wire contact 214, between the wire contact 214 and the connector 210.

[0049] Figure 9 illustrates another view of the end effector 200 including a first camera 202 and a second camera 204, wherein the two cameras are arranged to capture images from different viewing angles of a wire contact 114 of a wire attached by the wire gripper 208. Additionally illustrated is the separation device 219 as described herein to facilitate visibility of the available wire contact insertion holes of a connector so that wire contact alignment and insertion can be performed precisely and effectively. .

[0050] The embodiments described above rely on visually identifying available wire contact insertion holes for aligning and inserting wire contacts into a connector. However, as illustrated in Figure 10, connectors that have previously installed wires make identifying available wire contact insertion holes difficult. 10 illustrates two views of a plurality of wires 306 or a “bundle of wires” extending from a connector 310. As shown, no apparent wire contact insertion holes obscure any available wire contact insertion holes. Also illustrated in Figure 10 is wire gripper 308 together with wire 311 and wire contact 314, positioned to begin the alignment and insertion process. Additionally illustrated is the separation device 319, positioned with the wire gripper 308 above the plurality of wires 306. Although the example embodiments described here generally represent the separation of two or more wires previously connected to a connector, the separation device of the embodiments example may be used for as little as a previously connected wire, whereby a single wire may be previously connected to a connector, and the separating device may serve to push the single, previously connected wire away from a path of a contact of wire to be installed.

[0051] The separation device 319 includes a first separation element 319A and a second separation element 319B, as shown in figure 10. The process of inserting a wire contact 314 into an available wire contact insertion hole of the Connector 310 begins as shown in Figure 10 with the wire gripper 308 and the separation device 319 positioned above the plurality of wires 306. Although the illustrated embodiment includes many wires in the plurality of wires, embodiments of the separation device 319 can be used with any number of wires already inserted into connector 310. Further, as will be recognized by a person of ordinary skill in the art, the process described herein can be used without wires previously connected to the connector without change; however, the separation device 319 will not merely have any wires to separate in such an operation. Thus, the process described here can be used to insert each wire contact into a connector without deviating from the process.

[0052] The wire gripper 308 and the wire separation device 319, illustrated in figure 10, are positioned vertically above an insertion axis of the wire contact insertion hole, into which the wire contact is to be inserted . Although a connector may be assembled with wires and their respective wire contacts inserted into any available insertion hole, when the wires do not differ between the plurality of wires, the connector assembly often depends on the selection of a particular wire and contact. wire to be inserted into a specific designated wire contact insertion hole. As such, when a wire is clamped by the wire gripper 308, a designated wire contact insertion hole is generally known from the wire contact insertion hole arrangement of the connector. Thus, the end effector can position the wire gripper 308 and the wire separation device 319 directly above the geometric axis, along which the wire contact 314 will be inserted into the designated wire contact insertion hole. In this position illustrated in Figure 10, the separation device 319 is positioned behind the wire gripper 308 with respect to the connector 310.

[0053] Figure 11 illustrates the separation device 319 moved from behind the wire gripper 308 with respect to the connector 310 to a position in front of the wire gripper, between the wire gripper and the connector. According to some embodiments, the separation device 319 may begin at this position when the end effector is moved to the position above the wire contact insertion axis 314 in the designated wire contact insertion hole.

[0054] Figure 12 illustrates the next step of the process, in which the end effector descends and directs the separating device 319, including the first separating element 319A and the second separating element 319B, into the plurality of wires 306, separating or dividing the plurality of wires. The wire gripper 308 descends with the separator device 319 positioned laterally in front of the wire gripper 308 with respect to the connector 310 in order to protect the wire contact 14 of the plurality of wires 306 when the robot end effector moves the wire contact. wire 314 into position with the wire contact axially aligned with the designated wire contact insertion hole. The end effector positions the wire gripper 308 so that the wire contact 314 is disposed along an insertion axis in the connector 310. In this position, the wire contact 314 is axially aligned with the wire contact insertion hole. designated thread. In this step of the process, the separation device 319 remains in front of the wire gripper 308 with respect to the connector 310, with the point at which the first separation element 319A and the second separation element 319B positioned below the wire contact 314 to separating the plurality of wires 306 to accommodate the wire contact 314 at the position where the wire contact is axially aligned with the designated wire contact insertion hole.

[0055] The process continues with inserting wire contact into the designated wire contact insertion hole. This process may follow the finite iterative alignment process described above, with the cameras having visibility to the designated wire contact insertion hole due to separation of the plurality of wires 306 using the separator device 319. According to one embodiment of For example, the three-dimensional position of the designated wire contact insertion hole can be projected onto camera images, such as images from cameras near the wire gripper. The projection provides an estimate of the hole location within the image. A computer vision method finds a refined hole location given each camera image, such as through the process described above. The wire contact insertion holes inside the connector can be identified from the images and listed, just like in a temporary memory. To refine the target hole location, the location in a list of wire contact insertion holes closest to the three-dimensional projection of the designated wire contact insertion hole is chosen for the visual iterative alignment process. Embodiments optionally employ a maximum limiting distance from the nearest wire contact insertion hole, which is visually identified with respect to the three-dimensional projection of the designated wire contact insertion hole. In such an embodiment, if a detected/identified closest wire contact insertion hole to the three-dimensional projection is more than a threshold distance away (e.g., 20 pixels), the controller targets the projected location as the insertion hole. of designated wire contact without visual refinement. The projections and refinements can be computed for a multiplicity of cameras, preferably a pair of cameras close to the wire gripper.

[0056] Given the multiplicity of wire contact insertion holes in an image, a robot end effector offset is optionally computed such that the line extending from the wire contact intersects with the designated wire contact insertion hole in each image. According to an example embodiment, images are captured, and displacements are computed and executed until the wire contact aligns with the designated wire contact insertion hole within a threshold distance, such as within 0.5 millimeters. . Once alignment is accomplished, the wire gripper 308 is advanced toward the connector 310 by the robot end effector, which carries with it the separating device 319 that moves in concert with the wire gripper 308. The wire gripper 308 wire 308 inserts wire contact 314 into the designated wire contact insertion hole of the connector.

[0057] Figure 13 illustrates the next step in the process, whereby the wire separation device moves relative to the wire gripper 308, with the first separation element 319A and the second separation element 319B moving in front of the wire gripper 308 with respect to connector 310 behind the wire gripper with respect to connector. Movement of the separator device 319 behind the wire gripper 308 prevents the separator device from interfering with the wire contact insertion process, which may include a tip of the wire gripper 308 penetrating the grommet of the connector 310. The process Insertion begins by moving the wire contact 314 toward the surface of the connector 310 until the wire contact tip enters the designated wire contact insertion hole of the connector.

[0058] Insertion of the wire contact 314 into the designated wire contact insertion hole is accomplished by the wire gripper 308 advancing in the direction to the connector 310 with the wire contact 314 appropriately aligned with the wire contact insertion hole designated. Figure 14 illustrates the wire gripper 308 advanced in the direction towards the connector 310 inserting the wire contact.

[0059] During insertion, the robot end effector and/or wire gripper 308 may include one or more sensors to determine one or more forces acting on wire 311 or wire contact 314. Forces may be sensed due to of the resistance encountered by the robot's driving force (e.g. a servo motor, a hydraulic pump, etc.). The forces may optionally be sensed by a pressure gauge arrangement which may be disposed on the wire gripper and configured to sense the resistance to movement of the wire gripper or wire/wire contact retained therein. Various other force sensing arrangements may be employed, when necessary, to determine the forces acting on the wire contact 314 of the wire 311 held by the wire gripper 308.

[0060] During insertion, the robot end effector and/or wire gripper monitors the insertion force, F. If the force is above a predetermined value, e.g., 16 Newtons, a value that may be dependent on the type contact type and connector type, insertion may be temporarily stopped. Once temporarily stopped, a determination is made regarding the depth of insertion. The insertion depth can be estimated based on the initial distance to the connector and the travel distance of the robot end effector. The initial distance can be estimated by vision, such as through the image processing described above of identifying the location of the connector with respect to the wire contact. If the insertion depth D is above a minimum depth DMIN, a pull test is conducted.

[0061] Pull test operation can be performed to confirm seating of the wire contact within the connector. For pull testing, the wire gripper can pull back on the wire, away from the connector, until a specific distance or force limit is reached. If a force limit is reached before the specified distance, then the wire contact is confirmed to be properly seated. If the specified distance is reached before the force limit is reached, the wire insertion has failed as it is determined that the wire is not completely seated.

[0062] Once the wire contact 314 is inserted into the designated wire contact insertion hole and the wire contact is confirmed to be seated, the wire gripper 308 opens to release the wire 311, and the wire gripper 311 opens. wire together with the first separator element 319A and second separator element 319B move away from the connector 310, as shown in figure 15. The wire gripper 308 remains engaged around the wire, as shown in 309. Then the wire gripper 308 remains engaged around the wire, as shown in 309. Wire 308 further opens, as shown in Figure 16, and the first separator element 319A and second separator element 319B move away to further separate the plurality of wires 306 from the bundle. At this point, the wire gripper 308 is disengaged from the wire 311, and the robot end effector moves vertically to disengage from the plurality of wires 306. This completes the insertion of the wire contact into the connector so that any additional wires can be retrieved and installed to complete the connector.

[0063] Although the embodiment described above with respect to figures 11 to 16 has generally described the process of robot end effector alignment of the wire contact directly above a geometric axis along which the wire contact can be inserted into the hole In accordance with some embodiments, access to the appropriate insertion path for a designated wire contact insertion hole is not directly above the insertion path. Since the embodiments described here are configured to insert wire contacts into a connector, when a plurality of wires are already connected to the connector, the path for an insertion axis along which a wire contact is inserted may need to be avoided. the previously inserted wires. 17 illustrates an example embodiment of a connector 410 including wire contact insertion holes 412 and occupied wire contact insertion holes 414. A better available path for the designated wire contact insertion hole 416 of the illustrated embodiment is a straight line, but not one directly above connector 410. The path of the wire contact as carried by the wire gripper is computed such that the distance d between any point on the line and any hole filled with a wire is maximized. Said differently, the path is determined that provides the widest cradle for the designated wire contact insertion hole. With the optimum line of the example embodiment, shown as line 420, at an angle α with respect to the vertical, the robot end effector with the wire gripper needs to be rotated at the same angle α with respect to the vertical. The wire gripper is rotated before moving downward along line 420 separating the previously inserted wires. Optionally, a better path available for the designated wire contact insertion hole may not be a straight line, but may include a curved path to efficiently avoid previously inserted connector wires.

[0064] When optimizing the approach angle, as shown in Figure 17, a restriction on the maximum angle is imposed to prevent collisions of the end effector with other connector supports and devices used to manage wire arrangement. An example maximum angle is 20-degrees. Figure 18 illustrates a pseudo code for optimizing the approach angle. The movement path is restricted to a plane parallel to the connector surface and ends at the target hole, so that this path is uniquely defined by the approach angle.

[0065] Figure 19 is a flowchart of a method for inserting a wire contact into a designated wire contact insertion hole of a connector that has two or more wires already connected to the connector. As shown, a robot having an end effector is controlled to position a wire contact near a connector using a wire gripper and an end effector separator device at 510. The robot is controlled to advance the separator device between two or more wires. previously inserted into the connector at 520. At 530, the robot is controlled to align the wire contact with the designated wire contact insertion hole of the connector. The robot is controlled at 540 to advance the wire contact in the direction toward the hole. of the connector's designated wire contact insertion hole and at least partially inserting the wire contact into the designated wire contact insertion hole. The robot is controlled at 550 to release the wire contact from the wire gripper. At 560, the robot is controlled to remove the wire gripper and separating device from between the two or more wires previously connected to the connector.

[0066] As described above, figures 7 and 19 illustrate flowcharts of a system, method, and computer program product, in accordance with example embodiments of the present invention. It will be understood that each block of the flowcharts, and combinations of blocks in the flowcharts, may be implemented by various means, such as hardware, firmware, processor, circuitry, and/or other devices associated with executing software, including one or more instruction instructions. computer program. For example, one or more of the procedures described above may be embodied by computer program instructions. In this regard, computer program instructions embodying the procedures described above may be stored by memory 38 of a system 30 employing an embodiment of the present invention and executed by the processing circuitry 36 of system 30. As will be recognized, Any such computer program instructions may be loaded into a computer or other programmable apparatus (e.g., hardware) to produce a machine, such that the resulting computer or other programmable apparatus implements the functions specified in the flowchart blocks. These computer program instructions may also be stored in a computer-readable memory, which may direct a computer or other programmable device to function in a particular manner, so that the instructions stored in the computer-readable memory produce an article of manufacture, the execution of which implements the function specified in the flowchart blocks. Computer program instructions may also be loaded into a computer or other programmable device to cause a series of operations to be performed on the computer or other programmable device to produce a computer-implemented process so that the instructions that are executed on the computer or other programmable device provide operations to implement the functions specified in the flowchart blocks.

[0067] Furthermore, the invention comprises examples in accordance with the following clauses: Clause 1. System for automatically inserting a wire contact into a designated wire contact insertion hole (116) of a connector (110), the system comprising: a robot (44) having an end effector (100), wherein the end effector comprises a wire gripper (108) retaining the wire contact (114) and a separating device (119); and a computing device (34), wherein the computing device is configured to: control the robot to position the wire gripper retaining the wire contact proximate to the connector; controlling the robot to advance the separating device between two or more wires (306) previously connected to the connector; controlling the robot to align the wire contact with the designated wire contact insertion hole of the connector; controlling the robot to advance the wire contact in the direction to the designated wire contact insertion hole of the connector and at least partially inserting the wire contact into the designated wire contact insertion hole; control the robot to release the wire contact from the wire gripper; and controlling the robot to remove the wire gripper and separating device from between the two or more wires previously connected to the connector.

[0068] Clause 2. System according to clause 1, wherein the computing device (34) configured to control the robot (44) to advance the separating device (119) between the two or more wires (306) previously connected to the connector is further configured to: control the robot to advance the separating device from a first position relative to the wire gripper (108) to a second position relative to the wire gripper, wherein the first position is further from the connector than the wire gripper, and wherein the second position is closer to the connector than the wire gripper; and controlling the robot to actuate the separating device between the two or more wires at a position between the wire gripper and the connector.

[0069] Clause 3. System according to clause 1 or 2, wherein the computing device configured to control the robot (44) to advance the separating device (119) between the two or more wires (306) previously connected to the connector is further configured to: control the robot to move the separator device from the second position relative to the wire gripper (108) to the first position relative to the wire gripper with the separator device engaged between the two or more wires previously connected to the connector.

[0070] Clause 4. System according to clause 1 to 3, wherein the computing device configured to control the robot (44) to advance the wire contact (114) in the direction to the wire contact insertion hole designated wire contact insertion hole (116) of the connector (110) and at least partially inserting the wire contact into the designated wire contact insertion hole further comprises causing the robot to: advance the wire contact in the direction to the designated wire contact insertion hole designated wire of the connector and at least partially insert the wire contact into the designated wire contact insertion hole between the two or more wires previously connected to the connector.

[0071] Clause 5. System according to clause 1, wherein the computing device (34) is further configured to: determine positions of occupied wire contact insertion holes (116) of the connector (110), wherein the occupied wire contact insertion holes are occupied with the two or more wires (306) previously connected to the connector; and identifying a path for an insertion axis of the designated wire contact insertion hole of the connector, wherein the path is perpendicular to the insertion axis.

[0072] Clause 6. System according to clause 1 or 5, wherein the computing device (34) configured to identify the path to the insertion axis of the designated wire contact insertion hole (116) of the connector ( 110), wherein the path is perpendicular to the insertion axis, is further configured to: identify the path to the insertion axis of the connector's designated wire contact insertion hole based on a maximum distance between the path and the least one of the occupied wire contact insertion holes of the connector.

[0073] Clause 7. System according to clause 1 or 5 to 6, wherein the computing device configured to identify the path to the insertion axis of the designated wire contact insertion hole (116) of the connector (110 ), wherein the path is perpendicular to the insertion axis is further configured to: identify an angle of the path to the insertion axis of the designated wire contact insertion hole of the connector with respect to the vertical geometric axis, wherein the device computing device configured to control the robot (44) to position the wire gripper (108) retaining the wire contact (114) near the connector is further configured to control the robot to rotate to the angle of the path with respect to the connector.

[0074] Clause 8. System according to clause 1, wherein the separating device (119) comprises a first separating element and a second separating element, wherein the computing device (34) configured to control the robot (44) to advance the separating device between the two or more wires (306) previously connected to the connector comprises the computing device configured to actuate a point at which the first separating element meets the second separating element between the two or more wires previously connected to the connector to the along a path to an insertion axis of the designated wire contact insertion hole (116) of the connector (110), wherein the path is perpendicular to the insertion axis.

[0075] Clause 9. Method for automatically inserting a wire contact (114) into a designated wire contact insertion hole (116) of a connector (110), the method comprising: controlling a robot (44) having a end effector (100) for positioning the wire contact near the connector using a wire gripper (108) and a separator device (119) from the end effector; controlling the robot to advance the separating device between two or more wires (306) previously connected to the connector; controlling the robot to align the wire contact with the designated wire contact insertion hole of the connector; controlling the robot to advance the wire contact in the direction to the designated wire contact insertion hole of the connector and at least partially inserting the wire contact into the designated wire contact insertion hole; control the robot to release the wire contact from the wire gripper; and controlling the robot to remove the wire gripper and separating device from between the two or more wires previously connected to the connector.

[0076] Clause 10. Method according to clause 9, wherein controlling the robot (44) to advance the separating device (119) between the two or more wires (306) previously connected to the connector comprises: controlling the robot to advance the separating device from a first position relative to the wire gripper (108) to a second position relative to the wire gripper, wherein the first position is further from the connector (110) than the wire gripper, and wherein the second position is closer to the connector than the wire gripper; and controlling the robot to actuate the separating device between the two or more wires at a position between the wire gripper and the connector.

[0077] Clause 11. Method according to clauses 9 to 10, wherein controlling the robot (44) to advance the separating device (119) between the two or more wires (306) previously connected to the connector (110) further comprises : controlling the robot to move the separating device from the second position relative to the wire gripper (108) to the first position relative to the wire gripper with the separating device engaged between the two or more wires previously connected to the connector.

[0078] Clause 12. Method according to clauses 9 to 11, wherein controlling the robot (44) to advance the wire contact (114) in the direction to the designated wire contact insertion hole (116) of the connector (110) and at least partially inserting the wire contact (114) into the designated wire contact insertion hole further comprises: advancing the wire contact in the direction to the designated wire contact insertion hole of the connector and at least partially insert the wire contact into the designated wire contact insertion hole between the two or more wires (306) previously connected to the connector.

[0079] Clause 13. Method according to clause 9, further comprising: determining positions of occupied wire contact insertion holes (116) of the connector (110), wherein the occupied wire contact insertion holes are occupied with the two or more wires (306) previously connected to the connector (110); and identifying a path for an insertion axis of the designated wire contact insertion hole of the connector, wherein the path is perpendicular to the insertion axis.

[0080] Clause 14. Method according to clauses 9 or 13, wherein identifying the path to the geometric axis of insertion of the designated wire contact insertion hole (116) of the connector (110), wherein the path is perpendicular to the insertion axis, further comprises: identifying the path to the insertion axis of the designated wire contact insertion hole of the connector based on a maximum distance between the path and at least one of the occupied wire contact insertion holes of the connector.

[0081] Clause 15. Method according to clauses 9 or 13-14, wherein identifying the path to the geometric axis of insertion of the designated wire contact insertion hole (116) of the connector (110), wherein the path is perpendicular to the geometric axis of insertion, further comprises: identifying an angle of the path to the geometric axis of insertion of the designated wire contact insertion hole of the connector with respect to the vertical geometric axis, whereby controlling the robot (44) to position the The wire gripper (108) retaining the wire contact (114) near the connector further comprises controlling the robot to rotate to the angle of the path with respect to the connector.

[0082] Clause 16. Method according to clause 9, wherein the separating device (119) comprises a first separating element and a second separating element, wherein controlling the robot (44) to advance the separating device between two or more wires (306) previously connected to the connector (110) comprises actuating a point at which the first separating element meets the second separating element between the two or more wires previously connected to the connector along a path to a geometric axis of insertion of the hole. insertion of designated wire contact of the connector, where the path is perpendicular to the geometric axis of insertion.

[0083] Clause 17. Apparatus comprising at least one processor (36) and at least one memory (38) including computer program code, the at least one memory and computer program code configured to, with the processor, cause that the apparatus at least: controls a robot (44) having an end effector (100) to position a wire contact (114) near a connector (110) using a wire gripper (108) and a separating device (119) of the terminal effector; controlling the robot to advance the separating device between two or more wires (306) previously connected to the connector; controlling the robot to align the wire contact with a designated wire contact insertion hole (116) of the connector; controlling the robot to advance the wire contact in the direction to the designated wire contact insertion hole of the connector and at least partially inserting the wire contact into the designated wire contact insertion hole; control the robot to release the wire contact from the wire gripper; and controlling the robot to remove the wire gripper and separating device from between the two or more wires previously connected to the connector.

[0084] Clause 18. Apparatus according to clause 17, wherein causing the apparatus to control the robot (44) to advance the separating device (119) between the two or more wires (306) previously connected to the connector comprises causing than the apparatus: control the robot to advance the separating device (119) from a first position relative to the wire gripper (108) to a second position relative to the wire gripper, wherein the first position is further away from the connector (110) than the wire gripper, and wherein the second position is closer to the connector than the wire gripper; and control the robot to actuate the separating device between the two or more wires at a position between the wire gripper and the connector.

[0085] Clause 19. Apparatus according to clauses 17 to 18, wherein causing the apparatus to control the robot (44) advance the separating device (119) between the two or more wires (306) previously connected to the connector ( 110) further comprises causing the apparatus to: control the robot to move the separating device from the second position relative to the wire gripper to the first position relative to the wire gripper with the separating device engaged between the two or more wires previously connected to the connector .

[0086] Clause 20. Apparatus according to clauses 17 to 19, wherein causing the apparatus to control the robot (44) to advance the wire contact (114) in the direction to the designated wire contact insertion hole ( 116) of the connector (110) and at least partially inserting the wire contact into the designated wire contact insertion hole further comprises causing the apparatus to: advance the wire contact in the direction to the designated wire contact insertion hole of the connector and at least partially insert the wire contact into the designated wire contact insertion hole between the two or more wires previously connected to the connector.

[0087] Consequently, the flowchart blocks support combinations of means for carrying out the specified functions and combinations of operations for carrying out the specified functions for carrying out the specified functions. It will also be understood that one or more blocks of the flowcharts, and combinations of blocks in the flowcharts, may be implemented by computer systems based on special purpose hardware, which perform the specified functions, or combinations of special purpose hardware and computer instructions.

[0088] In some embodiments, certain operations of the above operations can be modified and also amplified. Additionally, in some embodiments, additional operations may be included. Modifications, additions, or amplifications to the above operations may be performed in any order and in any combination.

[0089] Many modifications and other embodiments of the inventions set forth here will come to the mind of a person skilled in the art having the benefit of the teachings set forth in the foregoing descriptions and associated drawings. Accordingly, it is to be understood that the present application is not to be limited to the specific embodiments described and that modifications and other embodiments are intended to be included within the scope of the appended claims. Furthermore, although the foregoing descriptions and associated drawings describe example embodiments in the context of certain example combinations of elements and/or functions, it should be recognized that different combinations of elements and/or functions may be provided by alternative embodiments without departing from the scope of the attached claims. In this regard, for example, different combinations of elements and/or functions than those explicitly described above are also contemplated, as can be set out in some of the attached claims. Although specific terms are employed here, they are used only in a generic and descriptive sense and not for limiting purposes.

Claims (10)

1. System for automatically inserting a wire contact into a designated wire contact insertion hole (116) of a connector (110), characterized in that the system comprises: a robot (44) having a terminal effector ( 100), wherein the end effector comprises a wire gripper (108) retaining the wire contact (114) and a separator device (119); and a computing device (34), wherein the computing device is configured to: control the robot to position the wire gripper retaining the wire contact proximate to the connector; controlling the robot to advance the separating device between two or more wires (306) previously connected to the connector; controlling the robot to align the wire contact with the designated wire contact insertion hole of the connector; controlling the robot to advance the wire contact in the direction to the designated wire contact insertion hole of the connector and at least partially inserting the wire contact into the designated wire contact insertion hole; control the robot to release the wire contact from the wire gripper; and controlling the robot to remove the wire gripper and separating device from between the two or more wires previously connected to the connector. 2. System according to claim 1, characterized by the fact that the computing device (34) configured to control the robot (44) to advance the separating device (119) between the two or more wires (306) previously connected to the connector is further configured to: control the robot to advance the separating device from a first position relative to the wire gripper (108) to a second position relative to the wire gripper, wherein the first position is further from the connector than the gripper of wire, and wherein the second position is closer to the connector than the wire gripper; and controlling the robot to actuate the separating device between the two or more wires at a position between the wire gripper and the connector. 3. System according to claim 1 or 2, characterized by the fact that the computing device configured to control the robot (44) to advance the separating device (119) between the two or more wires (306) previously connected to the connector is further configured to: control the robot to move the separator device from the second position relative to the wire gripper (108) to the first position relative to the wire gripper with the separator device engaged between the two or more wires previously connected to the connector. 4. System according to any one of claims 1 to 3, characterized by the fact that the computing device configured to control the robot (44) to advance the wire contact (114) in the direction to the wire contact insertion hole. designated wire (116) of the connector (110) and at least partially inserting the wire contact into the designated wire contact insertion hole further comprises causing the robot to: advance the wire contact in the direction to the contact insertion hole designated wire contact hole of the connector and at least partially insert the wire contact into the designated wire contact insertion hole between the two or more wires previously connected to the connector. 5. System according to claim 1, characterized by the fact that the computing device (34) is further configured to: determine positions of occupied wire contact insertion holes (116) of the connector (110), wherein the occupied wire contact insertion holes are occupied with the two or more wires (306) previously connected to the connector; and identifying a path for an insertion axis of the designated wire contact insertion hole of the connector, wherein the path is perpendicular to the insertion axis. 6. System according to claim 1 or 5, characterized by the fact that the computing device (34), configured to identify the path to the insertion axis of the designated wire contact insertion hole (116) of the connector ( 110), wherein the path is perpendicular to the insertion axis, is further configured to: identify the path to the insertion axis of the connector's designated wire contact insertion hole based on a maximum distance between the path and the least one of the occupied wire contact insertion holes of the connector. 7. System according to claim 1, 5 or 6, characterized by the fact that the computing device, configured to identify the path to the insertion axis of the designated wire contact insertion hole (116) of the connector (110 ), wherein the path is perpendicular to the insertion axis, is further configured to: identify an angle of the path to the insertion axis of the connector's designated wire contact insertion hole with respect to the vertical geometric axis, wherein the computing device configured to control the robot (44) to position the wire gripper (108) retaining the wire contact (114) near the connector is further configured to control the robot to rotate to the angle of the path with respect to the connector. 8. System according to claim 1, characterized in that the separating device (119) comprises a first separating element and a second separating element, wherein the computing device (34) is configured to control the robot (44) to advancing the separating device between the two or more wires (306) previously connected to the connector comprises the computing device configured to actuate a point at which the first separating element meets the second separating element between the two or more wires previously connected to the connector along of a path for an insertion axis of the designated wire contact insertion hole (116) of the connector (110), wherein the path is perpendicular to the insertion axis. 9. Method for automatically inserting a wire contact (114) into a designated wire contact insertion hole (116) of a connector (110), characterized in that the method comprises: controlling a robot (44) having an end effector (100) for positioning the wire contact near the connector using a wire gripper (108) and an end effector separator device (119); controlling the robot to advance the separating device between two or more wires (306) previously connected to the connector; controlling the robot to align the wire contact with the designated wire contact insertion hole of the connector; controlling the robot to advance the wire contact in the direction to the designated wire contact insertion hole of the connector and at least partially inserting the wire contact into the designated wire contact insertion hole; control the robot to release the wire contact from the wire gripper; and controlling the robot to remove the wire gripper and separating device from between the two or more wires previously connected to the connector. 10. Method according to claim 9, characterized by the fact that controlling the robot (44) to advance the separating device (119) between the two or more wires (306) previously connected to the connector comprises: controlling the robot to advance the separating device from a first position relative to the wire gripper (108) to a second position relative to the wire gripper, wherein the first position is further from the connector (110) than the wire gripper, and wherein the second position is closer to the connector than the wire gripper; and controlling the robot to actuate the separating device between the two or more wires at a position between the wire gripper and the connector.